Apparatus, method and system for sealing and insulating ventilation space

ABSTRACT

A bracket apparatus including a body, a rafter arm substantially adjacently connected to the body and two board arms substantially adjacently connected to the body. The two board arms are in parallel relation to each other. The present invention also includes an apparatus for installing foam board between two building structures. The apparatus includes a bracket of a predetermined size wherein the bracket fits about an edge of a foam board. The bracket attaches the foam board to building structures. A system for sealing and insulating ventilation space is also disclosed. The system includes at least two brackets that are a predetermined size and a foam board having predetermined dimensions such that the brackets secure and suspend the foam board to a building structure whereby a ventilation space is created. Also disclosed is a method for sealing and insulating a ventilation space.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of Provisional Patent Application Ser. No. 60/551,376 filed Mar. 9, 2004, which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to building construction and more particularly, to an apparatus, method and system for sealing and insulating ventilation space.

BACKGROUND INFORMATION

Ice dams commonly form on buildings in cold climates. Three conditions have to exist before an ice dam forms: (1) snow; (2) heat to melt the snow; and (3) cold to refreeze the melted snow into solid ice. As little as 50-60 mm of snow accumulation on the roof of a building can cause ice dams to form. Snow on the upper roof melts, runs under the blanket of snow to the roof's edge and refreezes into a dam of ice, which holds pools of more melted snow. This eventually backs up under shingles and leaks into the building.

The heat that causes these ice dams comes from heat leaking from the building's interior. The heat then melts the snow, which trickles down to the colder edge of the roof and refreezes into a dam. Every inch of snow that accumulates on the roof insulates the roof deck a little more, trapping more indoor heat and melting the bottom layer of snow. Frigid outdoor temperatures guarantee a fast and deep freeze at the eaves.

Loss of heat from the building interior occurs because of many reasons. First, with respect to residential homes, they have rafters sitting directly on top of exterior walls, and leave little room for insulation between the top of and the underside of the roof sheathing. Second, many builders do not spend enough effort installing features designed to prevent the movement of warm indoor air into this critical area.

Ice dams cause millions of dollars in damage every year. Much of the damage is apparent and easily recognizable: water stained ceilings, dislodged roof shingles, ice filled sagging gutters, peeling paint and damaged plaster. However, it is the non visible damage from the ice dams that is most serious. Insulation is damaged from the leaks. Roof leaks dampen attic insulation, which in the short term loses some of its insulating ability. However, over the long term, water-soaked insulation compresses so that, even after it dries, the insulation does not regain its original thickness. Thinner insulation means lower R-values. As more heat leaks from living areas into the attic, ice dams become more likely, causing additional damage to the building and destruction of the insulation.

Preventing ice dams is therefore tantamount to maintaining the heating efficiently of the building and preventing water damage. Keeping the roof cold is one method of preventing ice dams. This is done while the building is being constructed, by designing the building to have adequate ceiling insulation and effective roof ventilation.

Current conventional prevention includes increasing the insulation in the attic to at least 31 cm and closing the thermal shortcuts, i.e., openings that allow air to move from the heated part of the building into the attic. Additionally, creating adequate attic ventilation to remove any heat escapes into the attic. This is done by designing the attic to have one square foot of free ventilation opening for every 150 square feet of attic space. Ventilation is divided between eaves and the building ridge to take advantage of the fact that warm air rises.

Foam baffles are often used to increase the airflow. They are placed under the roof sheathing to direct outside air up the roof to the ridge vent. However, foam baffles have many disadvantages. First, the foam baffles allow outside air to leak through gaps between the baffles and into the fiberglass insulation, therefore reducing the R-value of the roof. The reduced R-value subsequently leads to heat loss which warms the vented air and causes ice dams. Second, the thin foam baffle is often crushed during installation, rendering it ineffective. Lastly, when the spacing between the rafters is less than 16 inches on center (a common situation in most homes) the baffle is too wide to use.

Accordingly, there is a need for system, method and apparatus that is sturdy, easily installed in buildings, that increases airflow out of the structure and that does not break easily during installation.

SUMMARY

In accordance with one aspect of the present invention, a bracket apparatus is disclosed. The bracket apparatus includes a body, a rafter arm substantially adjacently connected to the body and two board arms substantially adjacently connected to the body. The two board arms are in parallel relation to each other.

Some embodiments of this aspect of the invention include one or more of the following. Where the two board arms are at a predetermined distance from each other such that the two board arms can hold a foam board edge. Where the rafter arm rests over a rafter such that the apparatus is substantially secure on the rafter. Where the bracket is made from plastic.

In accordance with another aspect of the present invention, an apparatus for installing foam board between two building structures is disclosed. The apparatus includes a bracket of a predetermined size wherein the bracket fits about an edge of a foam board. The bracket attaches the foam board to building structures. Some embodiments of this aspect of the invention include one or more of the following. Where the bracket includes a body, a rafter arm substantially adjacently connected to the body and two board arms substantially adjacently connected to the body. The two board arms are in parallel relation to each other. Where the two board arms are at a predetermined distance from each other such that said two board arms can hold a foam board edge. Where the rafter arm rests over a building structure such that the apparatus is substantially secure on said building structure. Where the bracket is made from plastic.

In accordance with another aspect of the present invention, a system for sealing and insulating ventilation space. The system includes at least two brackets that are a predetermined size and a foam board having predetermined dimensions such that the brackets secure and suspend the foam board to a building structure whereby a ventilation space is created. Some embodiments of this aspect of the invention include one or more of the following. Where the bracket includes a body, a rafter arm substantially adjacently connected to the body and two board arms substantially adjacently connected to the body. The two board arms are in parallel relation to each other. Where the two board arms are at a predetermined distance from each other such that said two board arms can hold a foam board edge. Where the rafter arm rests over a building structure such that the apparatus is substantially secure on said building structure. Where the bracket is made from plastic. Where the foam board is fastened to the brackets.

In accordance with another aspect of the present invention, a method for sealing and insulating a ventilation space. The method includes one step of placing at least two brackets about edges of a foam board, the foam board is sized such that the foam board width with the width of the brackets is the same width as the distance between the two building structures. The method also includes the step of setting the foam board between the two building structures whereby the brackets secure the foam board suspended between the building structures. Some embodiments of this aspect of the invention include one or more of the following. Where the method includes the step of installing standard wind stop blocking between two building structures such that the top of the blocking is below the top of the building structures. Where the bottom of the foam board extends over the wind stop a predetermined distance past the outside wall plate. Where the foam board is fastened to the brackets.

These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, appended claims and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of the bracket apparatus of the present invention;

FIG. 2 is a section view of the system of the present invention attached to the rafter of a building;

FIG. 3 is a front view of the system of the present invention attached to the rafter of a building;

FIGS. 4-8 shows the steps of the preferred embodiment of the method of the present invention;

FIG. 4 shows the first step in installing the invention according to the preferred embodiment of the invention;

FIG. 5 shows the second step in installing the invention according to the preferred embodiment of the invention;

FIG. 6 shows the third step in installing the invention according to the preferred embodiment of the invention;

FIG. 7 shows the fourth step in installing the invention according to the preferred embodiment of the invention;

FIG. 8 shows the invention as installed into the rafters according to the preferred embodiment of the invention;

FIG. 9 is a section view of the invention in a roof section according to the preferred embodiment of the invention;

FIG. 10 is a section view of the invention in a wall section according to the preferred embodiment of the invention; and

FIG. 11 is a section view of the invention in a floor section according to the preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring first to FIG. 1, the bracket 10 is shown. The bracket 10 is also referred to as a vent clip. The dimensions given are for one preferred embodiment and are used for illustration and explanation only. Other dimensions for the bracket are contemplated and within the scope of the invention. Depending on the building structure dimensions and the foam board used, the bracket 10 dimensions will vary accordingly. Although the following description shows the invention as attached to rafters, the invention is intended to attach to any building structure where ventilation with insulation is desired. Although this description uses the terms “rafter”, the invention can be used with wall studs and floor joists among other building structures.

Still referring to FIG. 1, the bracket 10 includes a body 12, board arms 14, 16 and a rafter arm 18. In the preferred embodiment, the bracket 10 is made of plastic from a plastic extrusion process or injection molding. In other embodiments, the bracket 10 is made from metal, including but not limited to aluminum, steel, copper, nickel and iron. In its preferred embodiment, the bracket 10 has dimensions as follows. The body 12 is about 3 inches high, the rafter arm 18 is about 0.5 inches wide, and the board arms 14,16 are 0.5 inches wide. The length of the bracket 10 will vary depending on the length of the foam board. For conventional building structures, the length can vary from 24″ to 96″, but the bracket length can be shorter or longer, in fact the bracket can be any length, and the invention will perform as described herein.

The dimensions of the bracket 10 will vary depending on the thickness of the foam board. This is illustrated by the following description of FIG. 2. In practice, the bracket 10 fits along the outer edges of the foam board 20. The board arms 14,16 hold the foam board 20 around the width of the foam board 20. Thus, the distance between the board arms 14,16 will be directly dependent on the thickness of the foam board 20. The board arms 14, 16 hold the foam board in place. In some embodiments, the board arms 14, 16 fit securely around the foam board 20. The rafter arm 18 sits on the rafter (or other building structure) 22 which is part of the building's structure. The rafter arm 18 secures the foam board 20 however does not necessarily permanently secure the foam board 20. The rafter arm 18, in the preferred embodiment maintains the bracket 10 and foam board 20 in the desired position. Between the rafters 22, fiberglass insulation 24 is installed. The bracket 10 thus allows for easily connecting the foam board 20 to the rafters 22 and holds the foam board 20 between the rafters 22 and above the insulation 24. The distance from the rafter arm 18 to the board arm 14 provides a space between the foam board and the roof sheathing. This is the venting space. This distance can be modified to provide greater or less vent space.

Referring next to FIG. 3, a top view of the bracket 10 holding the foam board 20 and connected to the rafters 22 is shown. This view additionally illustrates that the bracket 10, in the preferred embodiment, extends the full length of the foam board 20. The foam board 20 can be any length desired. The bracket 10 will vary depending on the length of the foam board 20.

Although as depicted in FIG. 3 the clip 10 extends the full length of the foam board 20, however, in other embodiments, the bracket 10 only partially covers the long edges of the foam board 20.

The system for sealing and insulating ventilation space shown in FIGS. 1-3 depict a foam board 20 having a particular thickness. However, the thickness of the foam board 20 can vary, in fact, the foam board 20 can be any thickness desired. In the preferred embodiment, the foam board 20 has a thickness of between ¾″ and 4″, which are the thicknesses of foam board currently available from regular distributors. However, the foam board 20 thickness could be any thickness desired.

The invention can be installed into any building structure and works with conventional designs for rafters and trusses. The invention works to create a continuous and sealed and insulated vent space under the roof sheathing by suspending a foam board between rafters and trusses or along a wall by suspending it between wall studs and wall board. This system stops outside vent air from infiltrating the fiberglass insulation. The vent space created has a larger volume than existing baffle vents, which increases air flow, keeps roofs “cold” and eliminates ice dams and superheating. Using the present invention, R-values will increase.

When the invention is installed in the walls or the floors, it also works to create a continuous and insulated and sealed vent space, beside the wall and under the floor respectively, by suspending a foam board between building structures (frame). The invention supports radiant tubing and increases R-values.

Referring now to FIGS. 4-8, the preferred embodiment of the method of installation of the present invention is shown. The method is described with respect to the invention's use with rafters and trusses, but this method is similar as applies to walls and floors. Referring first to FIG. 4, a frame roof with trusses and rafters 22 in a conventional design is shown. Standard wind stop blocking 28 is installed between the rafters at the wall plate. The wind stop blocking 28 is kept below the top of the rafter. The distance below the rafter varies depending on the thickness of the foam board (not shown). For example, in one embodiment, the foam board thickness is 1^(1/2)″ and the wind stop blocking 28 is kept 3^(1/8)″) below the top of the rafter. Referring next to FIG. 5, to prepare the correct size foam board, the distance 30 between each rafter bay is first determined. The thickness of two brackets is then subtracted from the distance 30, and the resulting dimension is the required foam board width.

Referring next to FIG. 6, the brackets 10 are then placed on the long edges of the foam board 20. Next, as shown in FIG. 7, the foam board 20 is suspended between the rafter 22 by placing the clip 10 onto the rafter 22. The foam board 20 can be any length, but in the preferred embodiment, the foam board 20 extends up the roof (not shown) until it extends about 12 inches above the top of the attic insulation (not shown). With respect to cathedral applications, the foam board 20 extends all the way to the ridge.

Referring now to FIG. 8, the foam board 20 and brackets 10 are connected to the rafters 22 by friction fit. In some embodiments, when needed, staples are used to secure the foam board 20 and brackets 10 to the rafter, and in other embodiments, other fasteners are used. In still other embodiments, the brackets 10 are attached to the rafters 22 by nailing, tacking or gluing.

Following the installation of the invention, sheathing is applied on the roof per standard practices over vent. More vent can be added, as required, as sheathing continues up the roof.

Referring now to FIG. 9, a roof section is shown to exemplify the invention as installed between the rafters of a building. The foam board 20 and brackets 10 are installed between each rafter. In the preferred embodiment, a 1½ inch air space 32 is created. The size of the air space 32 is determined by the length of the clip body.

Although the invention has been shown as used in the rafters of a building, the invention can also be used in the walls or floors of buildings, or anywhere else where foam insulation is used. Referring now to FIG. 10, an embodiment of the present invention is shown where the invention is used in the walls of a building. The installation would be similar to the installation into the rafters of the building. In this embodiment, the brackets 10 are secure on the wall studs 40 and provide a ventilation space between the foam board 20 and the wall board 42. Referring now to FIG. 11, an embodiment of the present invention is shown where the invention is used in the floor of a building. The installation would be similar to the installation into the rafters of the building. In this embodiment, the brackets 10 are secure on the floor joist 44 and provide a ventilation space between the foam board 20 and the floor board 46.

While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention. 

1. An bracket apparatus comprising: a body; a rafter arm substantially adjacently connected to said body; and two board arms substantially adjacently connected to said body, said two board arms being in parallel relation to each other.
 2. The apparatus of claim 1 wherein said two board arms are at a predetermined distance from each other such that said two board arms can hold a foam board edge.
 3. The apparatus of claim 2 wherein said rafter arm rests over a rafter such that the apparatus is substantially secure on said rafter.
 4. The apparatus of claim 3 wherein said bracket is made from plastic.
 5. An apparatus for installing foam board between building structures comprising: a bracket of a predetermined size wherein said bracket fits about an edge of a foam board and whereby said bracket attaches said foam board to conventional building structures.
 6. The apparatus of claim 5 wherein said bracket further comprising: a body; a rafter arm substantially adjacently connected to said body; and two board arms substantially adjacently connected to said body, said two board arms being in parallel relation to each other.
 7. The apparatus of claim 6 wherein said two board arms are at a predetermined distance from each other such that said two board arms can hold a foam board edge.
 8. The apparatus of claim 7 wherein said rafter arm rests over a building structure such that the apparatus is substantially secure on said building structure.
 9. The apparatus of claim 8 wherein said bracket is made from plastic.
 10. A system for sealing and insulating ventilation space comprising: at least two brackets; and a foam board having predetermined dimensions wherein the brackets secure and suspend the foam board to a building structure whereby a ventilation space is created.
 11. The system of claim 10 wherein said brackets further comprising: a body; a rafter arm substantially adjacently connected to said body; and two board arms substantially adjacently connected to said body, said two board arms being in parallel relation to each other.
 12. The system of claim 11 wherein said two board arms are at a predetermined distance from each other such that said two board arms can hold said foam board.
 13. The system of claim 12 wherein said rafter arm rests over a rafter such that the apparatus is substantially secure on said rafter.
 14. The system of claim 10 wherein said foam board is fastened to said brackets.
 15. The apparatus of claim 13 wherein said bracket is made from plastic
 16. A method for sealing and insulating a ventilation space comprising the steps of: placing at least two brackets about edges of a foam board, said foam board is sized such that a width of said foam board with a width of said brackets is the same width as the distance between two building structures; and setting said foam board between said two building structures whereby said brackets secure said foam board suspended between said two building structures.
 17. The method of claim 16 further comprising the step of installing standard wind stop blocking between said two building structures such that top of said blocking is below top of said two building structures.
 18. The method of claim 17 further comprising wherein said bottom of said foam board extends over said wind stop a predetermined distance past outside wall plate.
 19. The method of claim 18 further comprising wherein said foam board is fastened to said brackets. 